Metal-Matrix Composites Reinforced with a Refractory Metal

ABSTRACT

A metal matrix composite tool that includes a hard composite portion comprising a reinforcement material infiltrated with a binder material, wherein the reinforcement material comprises a refractory metal component dispersed with reinforcing particles, wherein a surface roughness of the reinforcing particles is at least two times greater than the refractory metal component, wherein the refractory metal component has a failure strain of at least 0.05 and a shear modulus of 200 GPa or less, and wherein the reinforcing particles have a failure strain of 0.01 or less but at least five times less than the failure strain of the refractory metal component, and the reinforcing particles have a shear modulus of greater than 200 GPa and at least two times greater than the shear modulus of the refractory metal component. The reinforcing particles may comprise an intermetallic, a boride, a carbide, a nitride, an oxide, a ceramic, and/or a diamond.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is related to and claims priority to U.S.

Provisional Patent App. Ser. No. 62/135,817 filed on Mar. 20, 2015.

BACKGROUND

A wide variety of tools are commonly used in the oil and gas industryfor forming wellbores, in completing drilled wellbores, and in producinghydrocarbons from completed wellbores. Examples of such tools includecutting tools, such as drill bits, mills, and borehole reamers. Thesedownhole tools, and several other types of tools outside the realm ofthe oil and gas industry, are often formed as metal matrix composites(MMCs) and frequently referred to as “MMC tools.”

An MMC tool is typically manufactured by depositing matrix reinforcementmaterial into a mold and, more particularly, into a mold cavity definedwithin the mold and designed to form various external and internalfeatures of the MMC tool. Interior surfaces of the mold cavity, forexample, may be shaped to form desired external features of the MMCtool, and temporary displacement materials, such as consolidated sand orgraphite, may be positioned within interior portions of the mold cavityto form various internal (or external) features of the MMC tool. Ametered amount of binder material is then added to the mold cavity andthe mold is then placed within a furnace to liquefy the binder materialand thereby allow the binder material to infiltrate the reinforcingparticles of the matrix reinforcement material.

MMC tools are generally manufactured to be erosion-resistant and exhibithigh impact strength. However, depending on the particular materialsused, MMC tools can also be brittle and, as a result, stress cracks canoccur as a result of thermal stress experienced during manufacturing oroperation, or as a result of mechanical stress experienced duringoperation.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of thepresent disclosure, and should not be viewed as exclusive embodiments.The subject matter disclosed is capable of considerable modifications,alterations, combinations, and equivalents in form and function, withoutdeparting from the scope of this disclosure.

FIG. 1 is a perspective view of an exemplary drill bit that may befabricated in accordance with the principles of the present disclosure.

FIG. 2 is a cross-sectional side view of an exemplary mold assembly usedto form the drill bit of FIG. 1.

FIG. 3 is a cross-sectional view of the drill bit of FIG. 1.

FIG. 4 illustrates a cross-sectional side view of the drill bit of FIG.1 with one or more localized hard composite portions.

FIG. 5 illustrates a cross-sectional side view of the drill bit of FIG.1 as comprising a varied concentration of the hard composite portion.

FIG. 6 illustrates a cross-sectional side view of the drill bit of FIG.1 where the hard composite portion comprises a plurality of distinctlayers of varying concentration of the refractory metal component.

FIG. 7 is a plot that depicts measured transverse rupture strength ofthe hard composite portion of FIG. 2.

FIG. 8 is an exemplary drilling system that may employ one or moreprinciples of the present disclosure.

DETAILED DESCRIPTION

The present disclosure relates to tool manufacturing and, moreparticularly, to metal matrix composite tools reinforced with refractorymetal materials and associated methods of production and use relatedthereto.

Embodiments of the present disclosure describe the formation of a hardcomposite portion for a metal matrix composite tool, where the hardcomposite portion includes a reinforcement material that includesreinforcing particles dispersed with a refractory metal component. Thestrength, ductility, toughness, and erosion-resistance of the metalmatrix composite tools may be improved by incorporating an amount of therefractory metal component into the reinforcement material. Moreover,the addition of the refractory metal component to the reinforcementmaterial can potentially add significant strength and ductility to themetal matrix composite tool and possibly improve erosion resistance.

Embodiments of the present disclosure are applicable to any tool, part,or component formed as a metal matrix composite (MMC). For instance, theprinciples of the present disclosure may be applied to the fabricationof tools or parts commonly used in the oil and gas industry for theexploration and recovery of hydrocarbons. Such tools and parts include,but are not limited to, oilfield drill bits or cutting tools (e.g.,fixed-angle drill bits, roller-cone drill bits, coring drill bits,bi-center drill bits, impregnated drill bits, reamers, stabilizers, holeopeners, cutters), non-retrievable drilling components, aluminum drillbit bodies associated with casing drilling of wellbores, drill-stringstabilizers, cones for roller-cone drill bits, models for forging diesused to fabricate support arms for roller-cone drill bits, arms forfixed reamers, arms for expandable reamers, internal componentsassociated with expandable reamers, sleeves attached to an uphole end ofa rotary drill bit, rotary steering tools, logging-while-drilling tools,measurement-while-drilling tools, side-wall coring tools, fishingspears, washover tools, rotors, stators and/or housings for downholedrilling motors, blades and housings for downhole turbines, and otherdownhole tools having complex configurations and/or asymmetricgeometries associated with forming a wellbore.

The principles of the present disclosure, however, may be equallyapplicable to any type of MMC used in any industry or field. Forinstance, the methods described herein may also be applied tofabricating armor plating, automotive components (e.g., sleeves,cylinder liners, driveshafts, exhaust valves, brake rotors), bicycleframes, brake fins, wear pads, aerospace components (e.g., landing-gearcomponents, structural tubes, struts, shafts, links, ducts, waveguides,guide vanes, rotor-blade sleeves, ventral fins, actuators, exhauststructures, cases, frames, fuel nozzles), turbopump and compressorcomponents, a screen, a filter, and a porous catalyst, without departingfrom the scope of the disclosure. Those skilled in the art will readilyappreciate that the foregoing list is not a comprehensive listing, butonly exemplary. Accordingly, the foregoing listing of parts and/orcomponents should not be limiting to the scope of the presentdisclosure.

Referring to FIG. 1, illustrated is a perspective view of an example MMCtool 100 that may be fabricated in accordance with the principles of thepresent disclosure. The MMC tool 100 is generally depicted in FIG. 1 asa fixed-cutter drill bit that may be used in the oil and gas industry todrill wellbores. Accordingly, the MMC tool 100 will be referred toherein as the “drill bit 100,” but as indicated above, the drill bit 100may alternatively be replaced with any type of MMC tool or part used inthe oil and gas industry or any other industry, without departing fromthe scope of the disclosure.

As illustrated in FIG. 1, the drill bit 100 may provide a plurality ofcutter blades 102 angularly spaced from each other about thecircumference of a bit head 104. The bit head 104 is connected to ashank 106 to form a bit body 108. The shank 106 may be connected to thebit head 104 by welding, such as through laser arc welding that resultsin the formation of a weld 110 around a weld groove 112. The shank 106may further include a threaded pin 114, such as an American PetroleumInstitute (API) drill pipe thread used to connect the drill bit 100 todrill pipe (not shown).

In the depicted example, the drill bit 100 includes five cutter blades102 in which multiple recesses or pockets 116 are formed. A cuttingelement 118 (alternately referred to as a “cutter”) may be fixedlyinstalled within each recess 116. This can be done, for example, bybrazing each cutting element 118 into a corresponding recess 116. As thedrill bit 100 is rotated in use, the cutting elements 118 engage therock and underlying earthen materials, to dig, scrape or grind away thematerial of the formation being penetrated.

During drilling operations, drilling fluid or “mud” can be pumpeddownhole through a string of drill pipe (not shown) coupled to the drillbit 100 at the threaded pin 114. The drilling fluid circulates throughand out of the drill bit 100 at one or more nozzles 120 positioned innozzle openings 122 defined in the bit head 104. Junk slots 124 areformed between each angularly adjacent pair of cutter blades 102.Cuttings, downhole debris, formation fluids, drilling fluid, etc.

may flow through the junk slots 124 and circulate back to the wellsurface within an annulus formed between exterior portions of the stringof drill pipe and the inner wall of the wellbore being drilled.

FIG. 2 is a cross-sectional side view of a mold assembly 200 that may beused to form the drill bit 100 of FIG. 1. While the mold assembly 200 isshown and discussed as being used to help fabricate the drill bit 100, avariety of variations of the mold assembly 200 may be used to fabricateany of the MMC tools mentioned above, without departing from the scopeof the disclosure. As illustrated, the mold assembly 200 may includeseveral components such as a mold 202, a gauge ring 204, and a funnel206. In some embodiments, the funnel 206 may be operatively coupled tothe mold 202 via the gauge ring 204, such as by corresponding threadedengagements, as illustrated. In other embodiments, the gauge ring 204may be omitted from the mold assembly 200 and the funnel 206 may insteadbe operatively coupled directly to the mold 202, such as via acorresponding threaded engagement, without departing from the scope ofthe disclosure.

In some embodiments, as illustrated, the mold assembly 200 may furtherinclude a binder bowl 208 and a cap 210 placed above the funnel 206. Themold 202, the gauge ring 204, the funnel 206, the binder bowl 208, andthe cap 210 may each be made of or otherwise comprise graphite oralumina (Al₂O₃), for example, or other suitable materials. Aninfiltration chamber 212 may be defined within the mold assembly 200.Various techniques may be used to manufacture the mold assembly 200 andits components including, but not limited to, machining graphite blanksto produce the various components and thereby define the infiltrationchamber 212 to exhibit a negative or reverse profile of desired exteriorfeatures of the drill bit 100 (FIG. 1).

Materials, such as consolidated sand or graphite, may be positionedwithin the mold assembly 200 at desired locations to form variousfeatures of the drill bit 100 (FIG. 1). For example, one or more nozzleor leg displacements 214 (one shown) may be positioned to correspondwith desired locations and configurations of flow passageways definedthrough the drill bit 100 and their respective nozzle openings (i.e.,the nozzle openings 122 of FIG. 1). One or more junk slot displacements216 may also be positioned within the mold assembly 200 to correspondwith the junk slots 124 (FIG. 1). Moreover, a cylindrically shapedcentral displacement 218 may be placed on the leg displacements 214. Thenumber of leg displacements 214 extending from the central displacement218 will depend upon the desired number of flow passageways andcorresponding nozzle openings 122 in the drill bit 100. Further,cutter-pocket displacements 220 may be defined in the mold 202 orincluded therewith to form the cutter pockets 116 (FIG. 1). In theillustrated embodiment, the cutter-pocket displacements 220 are shown asforming an integral part of the mold 202.

After the desired displacement materials have been installed within themold assembly 300, a reinforcement material that includes reinforcingparticles 222 dispersed with a refractory metal component 224 may thenbe placed within or otherwise introduced into the mold assembly 300. Asused herein, the term “disperse” can refer to a homogeneous or aheterogeneous mixture or combination of two or more material, which inthis example is the reinforcing particles 222 and the refractory metalcomponent 224. The mixture of the reinforcing particles 222 and therefractory metal component 224 results in a custom reinforcementmaterial that may prove advantageous in adding strength and ductility tothe resulting drill bit 100 (FIG. 1) and may also improve erosionresistance.

In some embodiments, a mandrel 226 (alternately referred to as a “metalblank”) may be supported at least partially by the reinforcing particles222 and the refractory metal component 224 within the infiltrationchamber 212. More particularly, after a sufficient volume of thereinforcing particles 222 and the refractory metal component 224 hasbeen added to the mold assembly 200, the mandrel 226 may be situatedwithin mold assembly 200. The mandrel 226 may include an inside diameter228 that is greater than an outside diameter 230 of the centraldisplacement 218, and various fixtures (not expressly shown) may be usedto properly position the mandrel 226 within the mold assembly 200 at adesired location. The blend of the reinforcing particles 222 and therefractory metal component 224 may then be filled to a desired levelwithin the infiltration chamber 212 around the mandrel and the centraldisplacement 218.

A binder material 232 may then be placed on top of the mixture of thereinforcing particles 222 and the refractory metal component 224, themandrel 226, and the central displacement 218. In some embodiments, thebinder material 232 may be covered with a flux layer (not expresslyshown).

The amount of binder material 232 (and optional flux material) added tothe infiltration chamber 212 should be at least enough to infiltrate thereinforcing particles 222 and the refractory metal component 224 duringthe infiltration process. In some instances, some or all of the bindermaterial 232 may be placed in the binder bowl 208, which may be used todistribute the binder material 232 into the infiltration chamber 212 viavarious conduits 234 that extend therethrough. The cap 210 (if used) maythen be placed over the mold assembly 200.

The mold assembly 200 and the materials disposed therein may then bepreheated and subsequently placed in a furnace (not shown). When thefurnace temperature reaches the melting point of the binder material232, the binder material 232 will liquefy and proceed to infiltrate thereinforcing particles 222 and the refractory metal component 224. Aftera predetermined amount of time allotted for the liquefied bindermaterial 232 to infiltrate the reinforcing particles 222 and therefractory metal component 224, the mold assembly 200 may then beremoved from the furnace and cooled at a controlled rate.

FIG. 3 is a cross-sectional side view of the drill bit 100 of FIG. 1following the above-described infiltration process within the moldassembly 200 of FIG. 2. Similar numerals from FIG. 1 that are used inFIG. 3 refer to similar components or elements that will not bedescribed again. Once cooled, the mold assembly 200 of FIG. 2 may bebroken away to expose the bit body 108, which now includes a hardcomposite portion 302.

As illustrated, the shank 106 may be securely attached to the mandrel226 at the weld 110 and the mandrel 226 extends into and forms part ofthe bit body 108. The shank 106 defines a first fluid cavity 304 a thatfluidly communicates with a second fluid cavity 304 b corresponding tothe location of the central displacement 218 (FIG. 2). The second fluidcavity 304 b extends longitudinally into the bit body 108, and at leastone flow passageway 306 (one shown) may extend from the second fluidcavity 304 b to exterior portions of the bit body 108. The flowpassageway(s) 306 correspond to the location of the leg displacement(s)214 (FIG. 2). The nozzle openings 122 (one shown in FIG. 3) are definedat the ends of the flow passageway(s) 306 at the exterior portions ofthe bit body 108, and the pockets 116 are depicted as being formed aboutthe periphery of the bit body 108 and are shaped to receive the cuttingelements 118 (FIG. 1).

As shown in the enlarged detail view of FIG. 3, the hard compositeportion 302 may comprise the reinforcing particles 222 having therefractory metal component 224 dispersed therewith and infiltrated withthe binder material 232. The finished bit body 108, therefore, containsa volume of refractory metal-reinforced material, which may proveadvantageous in improving material strength, preventing crackpropagation, and/or increasing capacity for strain energy absorption(i.e., higher toughness). Also, the addition of the refractory metalcomponent 224 may prove advantageous in facilitating easier machining,grinding, and finishing of the infiltrated metal matrix compositematerial or tool.

Examples of suitable binder materials 232 used to infiltrate thereinforcing particles 222 and the refractory metal component 224include, but are not limited to, copper, nickel, cobalt, iron, aluminum,molybdenum, chromium, manganese, tin, zinc, lead, silicon, tungsten,boron, phosphorous, gold, silver, palladium, indium, any mixturethereof, any alloy thereof, and any combination thereof. Non-limitingexamples of the binder material 232 may include copper-phosphorus,copper-phosphorous-silver, copper-manganese-phosphorous, copper-nickel,copper-manganese-nickel, copper-manganese-zinc,copper-manganese-nickel-zinc, copper-nickel-indium,copper-tin-manganese-nickel, copper-tin-manganese-nickel-iron,gold-nickel, gold-palladium-nickel, gold-copper-nickel,silver-copper-zinc-nickel, silver-manganese, silver-copper-zinc-cadmium,silver-copper-tin, cobalt-silicon-chromium-nickel-tungsten,cobalt-silicon-chromium-nickel-tungsten-boron,manganese-nickel-cobalt-boron, nickel-silicon-chromium,nickel-chromium-silicon-manganese, nickel-chromium-silicon,nickel-silicon-boron, nickel-silicon-chromium-boron-iron,nickel-phosphorus, nickel-manganese, copper-aluminum,copper-aluminum-nickel, copper-aluminum-nickel-iron,copper-aluminum-nickel-zinc-tin-iron, and the like, and any combinationthereof. Examples of commercially-available binder materials 232include, but are not limited to, VIRGIN™ Binder 453D(copper-manganese-nickel-zinc, available from Belmont Metals, Inc.), andcopper-tin-manganese-nickel and copper-tin-manganese-nickel-iron grades516, 519, 523, 512, 518, and 520 available from ATI Firth Sterling.

The reinforcing particles 222 and the refractory metal component 224 maybe distinguished by physical properties like failure strain, shearmodulus, and solidus temperature. These physical property distinctionsmay provide for the improved strength, ductility, and erosion resistanceof the resulting drill bit 100.

As used herein, the term “failure strain” refers to the strain reachedby a material at ultimate failure, which may be determined by tensiletesting according to ASTM E8-15a for the refractory metal component 224or ASTM C1273-15 for the reinforcing particles 222. The reinforcingparticles 222 may have a failure strain of 0.01 or less (e.g., 0.001 to0.01, 0.005 to 0.01, or 0.001 to 0.005). The refractory metal component224 may have a failure strain of at least 0.05 (e.g., 0.05 to 0.5, 0.1to 0.5, or 0.05 to 0.1). In some instances, the failure strain of thereinforcing particles 222 may be at least five times less than thefailure strain of the refractory metal component 224 (e.g., 5 to 100times less, 5 to 50 time less, 5 to 25 times less, 10 to 50 times less,or 25 to 100 times less).

As used herein, the term “shear modulus” refers to the ratio of theshear force applied to a material divided by the deformation of thematerial under shear stress, which may be determined by ASTM E1875-13for the refractory metal component 224 or ASTM C1259-15 for thereinforcing particles 222 using a monolithic sample for each rather thana particle. The reinforcing particles 222 may have a shear modulus ofgreater than 200 GPa (e.g., greater than 200 GPa to 1000 GPa, greaterthan 200 GPa to 600 GPa, 400 GPa to 1000

GPa, 600 GPa to 1000 GPa, or 800 GPa to 1000 GPa). The refractory metalcomponent 224 may have a shear modulus of 200 GPa or less (e.g., 10 GPato 200 GPa, 10 GPa to 100 GPa, or 100 GPa to 200 GPa). In someinstances, the shear modulus of the reinforcing particles 222 may be atleast two times greater than the shear modulus of the refractory metalcomponents 320 (e.g., 2 to 40 times greater, 2 to 10 times greater, 5 to25 times greater, 10 to 40 times greater, or 25 to 40 times greater).

Further, a surface roughness of the refractory metal component 224 maybe smoother than the reinforcing particles 222, which may provide fasterbinder infiltration of the reinforcement material or tighter spacing ofthe reinforcement material. These advantages may result in a shorterheating or furnace cycle and more consistent strength, ductility, anderosion resistance properties in the hard composite portion 302. Surfaceroughness may be used as a measure of the smoothness of the individualparticles of the refractory metal component 224 and the individualreinforcing particles 222. As used herein, the term “surface roughness”refers to the average peak-to-valley distance as determined by laserprofilometry of the particle surfaces. Surface roughness of particlesmay depend on the size of the particles. In some instances, the surfaceroughness of the reinforcing particles 222 may be at least two timesgreater than (i.e., have a surface roughness at least two times greaterthan) the surface roughness of the refractory metal component 224 (e.g.,2 to 25 times greater, 5 to 10 times greater, or 10 to 25 timesgreater).

The inset bar chart shown in FIG. 3 provides an exemplarycross-sectional height profile comparison between the reinforcingparticles 222 and the refractory metal component 224. More specifically,the bar chart compares the average perimeter surface height (y-axis)with the distance around the perimeter surface (x-axis). The peaks andvalleys depicted in the bar chart correspond to the varying magnitude ofthe surface roughness as measured about the outer perimeter of thereinforcing particles 222 and the refractory metal component 224,respectively. The average peak-to-valley distance is calculated as theaverage peak height minus the average valley height. As can be seen inthe bar chart, the reinforcing particles 222 may exhibit averagepeak-to-valley distances that are at least two times greater than theaverage peak-to-valley distance of the refractory metal component 224.This equates to the reinforcing particles 222 having a surface roughnessof at least two times that of the refractory metal component.

Suitable reinforcing particles 222 include, but are not limited to,particles of intermetallics, borides, carbides, nitrides, oxides,ceramics, diamonds, and the like, or any combination thereof. Moreparticularly, examples of reinforcing particles 222 suitable for use inconjunction with the embodiments described herein may include particlesthat include, but are not limited to, nitrides, silicon nitrides, boronnitrides, cubic boron nitrides, natural diamonds, synthetic diamonds,cemented carbide, spherical carbides, low-alloy sintered materials, castcarbides, silicon carbides, boron carbides, cubic boron carbides,molybdenum carbides, titanium carbides, tantalum carbides, niobiumcarbides, chromium carbides, vanadium carbides, iron carbides, tungstencarbide (e.g., macrocrystalline tungsten carbide, cast tungsten carbide,crushed sintered tungsten carbide, carburized tungsten carbide, etc.),any mixture thereof, and any combination thereof. In some embodiments,the reinforcing particles 222 may be coated. For example, by way ofnon-limiting example, the reinforcing particles 222 may comprise diamondcoated with titanium.

In some embodiments, the reinforcing particles 222 described herein mayhave a diameter ranging from a lower limit of 1 micron, 10 microns, 50microns, or 100 microns to an upper limit of 1000 microns, 800 microns,500 microns, 400 microns, or 200 microns, wherein the diameter of thereinforcing particles 222 may range from any lower limit to any upperlimit and encompasses any subset therebetween.

While any of the reinforcing particles 222 mentioned herein may besuitable for use in the reinforcement material (e.g., particles ofintermetallics, borides, carbides, nitrides, oxides, ceramics, diamonds,etc.), one common type of reinforcing particle 222 is a tungsten carbide(WC) powder. However, WC, like carbide materials in general, can be hardand brittle. As such, it is sensitive to defects and prone tocatastrophic failure. Strength metrics for hard materials, such as WC,are highly statistical in preventing such failures, and carbide size andquality can also dramatically impact the performance of an MMC tool.

The strength, ductility, toughness, and erosion-resistance of the hardcomposite portion 302 of the resulting drill bit 100, or any of the MMCtools mentioned herein, may be improved and made more repeatable byincorporating or dispersing an amount of the refractory metal component224 into the reinforcement material. The refractory metal component 224may comprise a refractory metal as powder, particulate, shot, or acombination of any of the foregoing. As used herein, the term “shot”refers to particles having a diameter greater than 4 mm (e.g., greaterthan 4 mm to 16 mm). As used herein, the term “particulate” refers toparticles having a diameter of 250 microns to 4 mm. As used herein, theterm “powder” refers to particles having a diameter less than 250microns (e.g., 0.5 microns to less than 250 microns).

In some embodiments, the refractory metal component 224 described hereinmay have a diameter ranging from a lower limit of 1 micron, 10 microns,50 microns, or 100 microns to an upper limit of 16 mm, 10 mm, 5 mm, 1 mm500 microns, or 250 microns, wherein the diameter of the refractorymetal component 224 may range from any lower limit to any upper limitand encompasses any subset therebetween.

The refractory metal component 224 may comprise a refractory metal, arefractory metal alloy, or a combination of a refractory metal and arefractory metal alloy. Suitable refractory metals and refractory metalalloys include those with a solidus temperature greater than theinfiltration processing temperature, which may be around 1500° F., 2000°F., 2500° F., or 3000° F., or any subset or range falling therebetween.Example refractory metals that may be used as the refractory metalcomponent 224 may be grouped into sets corresponding to the requiredinfiltration processing temperature. Refractory metals that have asolidus temperature above 3000° F., for example, include tungsten,rhenium, osmium, tantalum, molybdenum, niobium, iridium, ruthenium,hafnium, boron, rhodium, vanadium, chromium, zirconium, platinum,titanium, and lutetium.

Example refractory metal alloys that may be used as the refractory metalcomponent 224 include alloys of the aforementioned refractory metals,such as tantalum-tungsten, tantalum-tungsten-molybdenum,tantalum-tungsten-rhenium, tantalum-tungsten-molybdenum-rhenium,tantalum-tungsten-zirconium, tungsten-rhenium, tungsten-molybdenum,tungsten-rhenium-molybdenum, tungsten-molybdenum-hafnium,tungsten-molybdenum-zirconium, tungsten-ruthenium, niobium-vanadium,niobium-vanadium-titanium, niobium-zirconium,niobium-tungsten-zirconium, niobium-hafnium-titanium, andniobium-tungsten-hafnium. Additionally, example refractory metal alloysinclude alloys wherein any of the aforementioned refractory metals isthe most prevalent element in the alloy. Examples for tungsten-basedalloys where tungsten is the most prevalent element in the alloy includetungsten-copper, tungsten-nickel-copper, tungsten-nickel-iron,tungsten-nickel-copper-iron, and tungsten-nickel-iron-molybdenum.

Refractory metals that have a solidus temperature above 2500° F. includethe refractory metals listed previously in addition to palladium,thulium, scandium, iron, yttrium, erbium, cobalt, holmium, nickel,silicon, and dysprosium. Example refractory metal alloys include alloysof the aforementioned refractory metals having a solidus temperatureabove 2500° F. and the refractory metals having a solidus temperatureabove 3000° F. Example nickel-based alloys include nickel alloyed withvanadium, chromium, molybdenum, tantalum, tungsten, rhenium, osmium, oriridium. Additionally, example refractory metal-based alloys includealloys wherein any of the aforementioned refractory metals is the mostprevalent element in the alloy. Examples for nickel-based alloys wherenickel is the most prevalent element in the alloy include nickel-copper,nickel-chromium, nickel-chromium-iron, nickel-chromium-molybdenum,nickel-molybdenum, HASTELLOY® alloys (i.e., nickel-chromium containingalloys, available from Haynes International), INCONEL® alloys (i.e.,austenitic nickel-chromium containing superalloys available from SpecialMetals Corporation), WASPALOYS® austenitic nickel-based superalloys),RENE® alloys (i.e., nickel-chromium containing alloys available fromAltemp Alloys, Inc.), HAYNES® alloys (i.e., nickel-chromium containingsuperalloys available from Haynes International), MP98T (i.e., anickel-copper-chromium superalloy available from SPS Technologies), TMSalloys, CMSX® alloys (i.e., nickel-based superalloys available from C-MGroup). Example iron-based alloys include steels, stainless steels,carbon steels, austenitic steels, ferritic steels, martensitic steels,precipitation-hardening steels, duplex stainless steels, andhypo-eutectoid steels.

Refractory metals that have a solidus temperature above 2000° F. includethe refractory metals listed previously in addition to terbium,gadolinium, beryllium, manganese, and uranium. Example refractorymetal-based alloys include alloys comprised of the aforementionedrefractory metals having a solidus temperature above 2000° F. and therefractory metals having a solidus temperature above 2500° and 3000° F.Additionally, example refractory metal-based alloys include alloyswherein any of the aforementioned refractory metals having a solidustemperature above 2000° F. is the most prevalent element in the alloy.Example alloys include INCOLOY® alloys (i.e., iron-nickel containingsuperalloys available from Mega Mex) and hyper-eutectoid steels.

Refractory metals that have a solidus temperature above 1500° F. includethe refractory metals listed previously in addition to copper, samarium,gold, neodymium, silver, germanium, praseodymium, lanthanum, calcium,europium, and ytterbium. Example refractory metal-based alloys includealloys comprised of the aforementioned refractory metals having asolidus temperature above 1500° F. and the refractory metals listedpreviously having a solidus temperature above 2000° F., 2500° and 3000°F. Additionally, example refractory metal-based alloys include alloyswherein any of the aforementioned refractory metals having a solidustemperature above 1500° F. is the most prevalent element in the alloy.

The refractory metal component 224 may be dispersed with the reinforcingparticles 222 to produce the reinforcement material by mixing, blending,or otherwise combining the refractory metal component 224 with thereinforcing particles 222. In some cases, the refractory metal component224 may be dispersed in the reinforcement material by mixing inagglomerations of the reinforcing particles 222 and/or the refractorymetal component 224. In other cases, the refractory metal component 224may be dispersed in the reinforcement material by loading one materialabove the other (in layers) and subsequently tapping, tamping,vibrating, shaking, etc. to produce a functionally graded mix of thereinforcing particles 222 and the refractory metal component 224in-situ. In yet other cases, the refractory metal component 224 may bedispersed in the reinforcement material using organics that allowloading of the separate components without segregation, which may proveadvantageous in making functional grading more controllable.

The refractory metal component 224 may be dispersed or otherwiseincluded in the reinforcement material over a range of concentrations,depending primarily on the desired properties of the resulting hardcomposite portion 302 (FIG. 3). For example, the hard composite portion302 may include the refractory metal component 224 at a concentrationranging from a lower limit of 1%, 3%, or 5% by weight of thereinforcement material of the reinforcement material to an upper limitof 40%, 30%, 20%, or 10% by weight of the reinforcement material,wherein the concentration of the refractory metal component 224 mayrange from any lower limit to any upper limit and encompasses any subsettherebetween. To be applicable to all types of MMC tools mentionedherein, however, the hard composite portion 302 may include therefractory metal component 224 or the reinforcing particles 222 at aconcentration ranging from anywhere between greater than 0% to less than100% by weight of the reinforcement material, without departing from thescope of the disclosure.

While certain metal powders have been added to reinforcement materialsas an infiltration aid, the refractory metal component 224 mixed withthe reinforcing particles 222 of the present disclosure works in afundamentally different way since the refractory metal component 224does not melt into the continuous binder phase in the resulting MMCtool. In most cases, the refractory metal component 224 does notinterdiffuse with the binder phase to an appreciable extent, therebyleaving the refractory metal component 224 to remain as ductilethird-phase particles in the resulting MMC tool after the infiltrationprocess.

In one specific embodiment, the reinforcing particles 222 may comprisetungsten carbide (WC) and the refractory metal component 224 maycomprise a tungsten (W) metal powder. Using tungsten metal powder as therefractory metal component 224 may be advantageous since it is harderand less reactive than most other metals due to its hardness andcorrosion resistance. As compared to the use of a softer (more ductile)metal, the tungsten metal powder provides a more rigid and repeatablespacing effect, which reduces the brittleness caused by carbides thatare fused close together. As a result, this reduces the amount ofductile binder material 232 that can deform under high stresses and/orstress concentrations thereby limiting carbide fracture due to excessivematrix deformation. The mean particle size and the particle sizedistribution of the tungsten metal powder can be used to achieve thisdesired spacing between the reinforcing particles 222 (e.g., WCparticles). Moreover, the lower reactivity of the binder material 232with tungsten metal powder may mitigate the formation of potentiallyunwanted intermetallics that might otherwise occur with the use of othertransition metals.

By way of non-limiting illustration, FIGS. 4-6 provide examples ofdispersing the refractory metal component 224 into the reinforcementmaterial in MMC tools and, more particularly, in the drill bit 100 ofFIGS. 1 and 3. One skilled in the art will recognize how to adapt theseteachings to other MMC tools or portions thereof in keeping with thescope of the disclosure.

FIG. 4 illustrates a cross-sectional side view of the drill bit 100where the bit body 108 comprises the hard composite portion 302 and oneor more localized hard composite portions 402, according to one or moreembodiments. The hard composite portion 302 in FIG. 4 may comprise amixture or blend of the reinforcing particles 222 (FIG. 3) and therefractory metal component 224 (FIG. 3), where the refractory metalcomponent 224 is included at a concentration ranging from a lower limitof 1%, 3%, or 5% by weight of the reinforcement material of thereinforcement material to an upper limit of 40%, 30%, 20%, or 10% byweight of the reinforcement material. In contrast, the localized hardcomposite portion 402 may comprise a mixture or blend of the reinforcingparticles 222 and the refractory metal component 224, where therefractory metal component 224 is included at higher concentrations likea concentration of about 80%, about 85%, about 90%, about 95%, or 100%by weight of the reinforcement material, wherein the concentration ofthe refractory metal component 224 may encompass any subsettherebetween. To be applicable to all types of MMC tools mentionedherein, however, the localized hard composite portion 402 may comprise amixture or blend of the reinforcing particles 222 and the refractorymetal component 224, where the reinforcing particles 222 or therefractory metal component 224 is included at a concentration rangingfrom anywhere between greater than 0% to less than 100% by weight of thereinforcement material, without departing from the scope of thedisclosure.

As illustrated, the localized hard composite portion 402 may belocalized in the bit body 108 at one or more locations with theremaining portion of the bit body 108 being formed by the hard compositeportion 302. The localized hard composite portion 402 is shown in FIG. 4as being located proximal the nozzle openings 122 and generally at anapex 404 of the drill bit 100, the two areas of the bit body 108 thattypically have an increased propensity for cracking. As used herein, theterm “apex” refers to the central portion of the exterior surface of thebit body 108 that engages the formation during drilling and generally ator near where the cutter blades 102 (FIG. 1) meet on the exteriorsurface of the bit body 108 to engage the formation during drilling. Inother embodiments, the localized hard composite portion 402 may belocalized in the bit body 108 at any of the interior regions, such asaround and/or near the metal blank 202, or at any area of geometrictransitions (e.g., blade roots, etc.). The localized hard compositeportion 402 may help mitigate crack initiation and propagation, whilealso manipulating the erosion properties of the bit body 108 because ofthe lower concentration of reinforcing particles 222 at the localizedareas.

FIG. 5 illustrates a cross-sectional side view of the drill bit 100 ascomprising a varying concentration of the hard composite portion 302within the bit body 108, in accordance with the teachings of the presentdisclosure. As shown by the degree of stippling in the bit body 108, theconcentration of the refractory metal component 224 in the hardcomposite portion 302 may increase from the apex 404 to the shank 106 ofthe bit body 108. In the illustrated embodiment, the lowestconcentration of the refractory metal component 224 is adjacent thenozzle openings 122 and the pockets 116 and the highest concentrationsthereof are adjacent the metal blank 202.

In alternative embodiments, however, the gradient of concentration ofthe refractory metal component 224 can be reversed where theconcentration of the refractory metal component 224 decreases from theapex 404 toward the shank 106. Moreover, while shown in FIG. 5 asvarying longitudinally within the bit body 108, the gradient in theconcentration of the refractory metal component 224 can alternatively bedesigned to vary radially or a combination of radially and vertically,without departing from the scope of the disclosure. Accordingly, thegradient of concentration of the refractory metal component 224 asdispersed within the reinforcement material may increase or decrease inany direction (i.e., radially, axially, longitudinally, laterally,circumferentially, angularly, and any combination thereof) through thedrill bit 100 (or any other type of MMC tool).

In some embodiments, the concentration change of the refractory metalcomponent 224 in the hard composite portion 302 may be gradual. In otherembodiments, however, the concentration change may be more distinct andthereby resemble layering or localization. For example, FIG. 6illustrates a cross-sectional side view of the drill bit 100 where thehard composite portion 302 comprises a plurality of distinct layers ofvarying concentration of the refractory metal component 224, accordingto one or more embodiments. More particularly, the hard compositeportion 302 is depicted in FIG. 6 as comprising layers 302 a, 302 b, and302 c. The first layer 302 a may exhibit the lowest concentration ofrefractory metal component 224 and is depicted as being located proximalthe nozzle openings 122 and the pockets 116. The third layer 302 c mayexhibit the highest concentration of refractory metal component 224 andis depicted as being located proximal the metal blank 202. The secondlayer 302 b with may exhibit a concentration of refractory metalcomponent 224 between that of the first and third layers 302 a,c andgenerally interposes said layers 302 a,c. Alternatively, theconcentration of the refractory metal component 224 in the hardcomposite portion layers 302 a-c may decrease from the apex 404 towardthe metal blank 202, without departing from the scope of the disclosure.

FIG. 7 is a plot 700 that depicts measured transverse rupture strength(TRS) of the hard composite portion 302 (FIG. 3). More particularly, theplot 700 depicts measured TRS when the hard composite portion 302 ismade from a blend of tungsten carbide (WC) powder as the reinforcingparticles 222 (FIG. 3) and tungsten metal powder (TMP) as the refractorymetal component 224 (FIG. 3). As illustrated, the TRS of the compositeWC powder and TMP increases with increasing addition of TMP. While thisincrease in strength is desirable, another important consideration isthe erosion and abrasion properties of the final hard composite portion302. To be of benefit in drill bits (e.g., the drill bit 100 of FIGS. 1and 3), for example, an optimal combination of high strength and higherosion-resistance must be found. With advancements in WC powdermanufacture, lower and lower erosion rates are achievable. Theseimproved WC powders, in combination with a TMP component, is now aviable option to create tough erosion-resistance MMC materials. Moreparticularly, in combination with localized blend concentrations asdescribed in conjunction with FIGS. 4-6, erosion-resistance propertiesof certain portions of the drill bits or other types of MMC tools may beretained or optimized, while toughness of other portions of the drillbit or other types of MMC tools may be optimized to prevent, delay, orslow crack initiation and propagation during bit manufacture and/oroperation.

FIG. 8 is a schematic of an exemplary drilling system 800 that mayemploy one or more principles of the present disclosure. Boreholes maybe created by drilling into the earth 802 using the drilling system 800.The drilling system 800 may be configured to drive a bottom holeassembly (BHA) 804 positioned or otherwise arranged at the bottom of adrill string 806 extended into the earth 802 from a derrick 808 arrangedat the surface 810. The derrick 808 includes a kelly 812 and a travelingblock 813 used to lower and raise the kelly 812 and the drill string806.

The BHA 804 may include a drill bit 814 operatively coupled to a toolstring 816 which may be moved axially within a drilled wellbore 818 asattached to the drill string 806. The drill bit 814 may be fabricatedand otherwise created in accordance with the principles of the presentdisclosure and, more particularly, with a reinforcement material thatincludes a refractory metal component 224 (FIG. 3) dispersed with thereinforcing particles 222 (FIG. 3). During operation, the drill bit 814penetrates the earth 802 and thereby creates the wellbore 818. The BHA804 provides directional control of the drill bit 814 as it advancesinto the earth 802. The tool string 816 can be semi-permanently mountedwith various measurement tools (not shown) such as, but not limited to,measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools,that may be configured to take downhole measurements of drillingconditions. In other embodiments, the measurement tools may beself-contained within the tool string 816, as shown in FIG. 8.

Fluid or “mud” from a mud tank 820 may be pumped downhole using a mudpump 822 powered by an adjacent power source, such as a prime mover ormotor 824. The mud may be pumped from the mud tank 820, through astandpipe 826, which feeds the mud into the drill string 806 and conveysthe same to the drill bit 814. The mud exits one or more nozzlesarranged in the drill bit 814 and in the process cools the drill bit814. After exiting the drill bit 814, the mud circulates back to thesurface 810 via the annulus defined between the wellbore 818 and thedrill string 806, and in the process returns drill cuttings and debristo the surface. The cuttings and mud mixture are passed through a flowline 828 and are processed such that a cleaned mud is returned down holethrough the standpipe 826 once again.

Although the drilling system 800 is shown and described with respect toa rotary drill system in FIG. 8, many types of drilling systems can beemployed in carrying out embodiments of the disclosure. For instance,drills and drill rigs used in embodiments of the disclosure may be usedonshore or offshore. Offshore oilrigs that may be used in accordancewith embodiments of the disclosure include, for example, floaters, fixedplatforms, gravity-based structures, drill ships, semi-submersibleplatforms, jack-up drilling rigs, tension-leg platforms, and the like.Embodiments of the disclosure can be applied to rigs ranging anywherefrom small in size and portable, to bulky and permanent.

Further, although described herein with respect to oil drilling, variousembodiments of the disclosure may be used in many other applications.For example, disclosed methods can be used in drilling for mineralexploration, environmental investigation, natural gas extraction,underground installation, mining operations, water wells, geothermalwells, and the like. Further, embodiments of the disclosure may be usedin weight-on-packers assemblies, in running liner hangers, in runningcompletion strings, etc., without departing from the scope of thedisclosure.

Embodiments disclosed herein include:

A. A metal matrix composite (MMC) tool that includes a hard compositeportion that comprises a reinforcement material infiltrated with abinder material, wherein the reinforcement material comprises arefractory metal component dispersed with reinforcing particles, whereinthe reinforcing particles are at least two times rougher than therefractory metal component, wherein the refractory metal component has afailure strain of at least 0.05 and a shear modulus of 200 GPa or less,and wherein the reinforcing particles have a failure strain of 0.01 orless but at least five times less than the failure strain of therefractory metal component, and the reinforcing particles have a shearmodulus of greater than 200 GPa and at least two times greater than theshear modulus of the refractory metal component.

B. A drill bit that includes a bit body, and a plurality of cuttingelements coupled to an exterior of the bit body, wherein at least aportion of the bit body comprises a hard composite portion thatcomprises a reinforcement material infiltrated with a binder material,wherein the reinforcement material comprises a refractory metalcomponent dispersed with reinforcing particles, wherein the reinforcingparticles are at least two times rougher than the refractory metalcomponent, wherein the refractory metal component has a failure strainof at least 0.05 and a shear modulus of 200 GPa or less, and wherein thereinforcing particles have a failure strain of 0.01 or less but at leastfive times less than the failure strain of the refractory metalcomponent, and the reinforcing particles have a shear modulus of greaterthan 200 GPa and at least two times greater than the shear modulus ofthe refractory metal component.

C. A drilling assembly that includes a drill string extendable from adrilling platform and into a wellbore, a drill bit attached to an end ofthe drill string, and a pump fluidly connected to the drill string andconfigured to circulate a drilling fluid to the drill bit and throughthe wellbore, wherein the drill bit comprises a bit body and a pluralityof cutting elements coupled to an exterior of the bit body, and whereinat least a portion of the bit body comprises a hard composite portionthat comprises a reinforcement material infiltrated with a bindermaterial, wherein the reinforcement material comprises a refractorymetal component dispersed with reinforcing particles, wherein thereinforcing particles are at least two times rougher than the refractorymetal component, wherein the refractory metal component has a failurestrain of at least 0.05 and a shear modulus of 200 GPa or less, andwherein the reinforcing particles have a failure strain of 0.01 or lessbut at least five times less than the failure strain of the refractorymetal component, and the reinforcing particles have a shear modulus ofgreater than 200 GPa and at least two times greater than the shearmodulus of the refractory metal component.

Each of embodiments A, B, and C may have one or more of the followingadditional elements in any combination: Element 1: wherein thereinforcing particles comprise particles of a material selected from thegroup consisting of an intermetallic, a boride, a carbide, a nitride, anoxide, a ceramic, diamond, and any combination thereof. Element 2:wherein the refractory metal component is selected from the groupconsisting of a refractory metal, a refractory metal alloy, and acombination of a refractory metal and a refractory metal alloy. Element3: wherein the refractory metal component has solidus temperaturegreater than 1500° F. and is selected from the group consisting oftungsten, rhenium, osmium, tantalum, molybdenum, niobium, iridium,ruthenium, hafnium, boron, rhodium, vanadium, chromium, zirconium,platinum, titanium, lutetium, palladium, thulium, scandium, iron,yttrium, erbium, cobalt, holmium, nickel, silicon, dysprosium, terbium,gadolinium, beryllium, manganese, copper, samarium, gold, neodymium,silver, germanium, praseodymium, lanthanum, calcium, europium,ytterbium, and any alloy thereof. Element 4: wherein the refractorymetal component is a tungsten metal powder and the reinforcing particlesare a tungsten carbide powder. Element 5: wherein the hard compositeportion comprises the refractory metal component at a concentrationranging from between 1% and 40% by weight of the reinforcement material.Element 6: wherein the reinforcement material is infiltrated with thebinder material at a temperature greater than a liquidus temperature ofthe binder material but lower than a solidus temperature of therefractory metal component. Element 7: wherein the hard compositeportion further comprises one or more localized hard composite portionscomprising the refractory metal component dispersed with the reinforcingparticles at a concentration ranging between 80% and 100% by weight ofreinforcement material. Element 8: wherein a gradient of concentrationof the refractory metal component progressively decreases in a directionthrough the hard composite portion. Element 9: wherein a gradient ofconcentration of the refractory metal component progressively increasesin a direction through the hard composite portion. Element 10: whereinthe hard composite portion comprises a plurality of distinct layers ofvarying concentration of the refractory metal component. Element 11:wherein the reinforcing particles are 2 to 25 times rougher than therefractory metal component. Element 12: wherein the refractory metalcomponent has a failure strain of 0.05 to 0.5, and wherein thereinforcing particles have a failure strain of 0.001 to 0.01 but 5-100times less than the failure strain of the refractory metal component.Element 13: wherein the refractory metal component has a shear modulusof 10 GPa to 200 GPa, and wherein the reinforcing particles have a shearmodulus of greater than 200 GPa to 1000 GPa and 2 to 40 times greaterthan the shear modulus of the refractory metal component. Element 14:wherein the refractory metal component has an average diameter of 1micron to 16 mm. Element 15: wherein the reinforcing particles have anaverage diameter of 1 micron to 1000 microns. Element 16: wherein therefractory metal component comprises a powder. Element 17: wherein therefractory metal component comprises particulates. Element 18: whereinthe refractory metal component comprises shot.

By way of non-limiting example, exemplary combinations applicable to A,B, and C include: Element 2 with Element 3; two or more of Elements14-18 in combination; Elements 5 and 7 in combination; one or more ofElements 14-18 in combination with one or more of Elements 1-2; two ormore of Elements 11-13 in combination; and combinations of theforegoing.

Therefore, the disclosed systems and methods are well adapted to attainthe ends and advantages mentioned as well as those that are inherenttherein. The particular embodiments disclosed above are illustrativeonly, as the teachings of the present disclosure may be modified andpracticed in different but equivalent manners apparent to those skilledin the art having the benefit of the teachings herein. Furthermore, nolimitations are intended to the details of construction or design hereinshown, other than as described in the claims below. It is thereforeevident that the particular illustrative embodiments disclosed above maybe altered, combined, or modified and all such variations are consideredwithin the scope of the present disclosure. The systems and methodsillustratively disclosed herein may suitably be practiced in the absenceof any element that is not specifically disclosed herein and/or anyoptional element disclosed herein. While compositions and methods aredescribed in terms of “comprising,” “containing,” or “including” variouscomponents or steps, the compositions and methods can also “consistessentially of” or “consist of” the various components and steps. Allnumbers and ranges disclosed above may vary by some amount. Whenever anumerical range with a lower limit and an upper limit is disclosed, anynumber and any included range falling within the range is specificallydisclosed. In particular, every range of values (of the form, “fromabout a to about b,” or, equivalently, “from approximately a to b,” or,equivalently, “from approximately a-b”) disclosed herein is to beunderstood to set forth every number and range encompassed within thebroader range of values. Also, the terms in the claims have their plain,ordinary meaning unless otherwise explicitly and clearly defined by thepatentee. Moreover, the indefinite articles “a” or “an,” as used in theclaims, are defined herein to mean one or more than one of the elementsthat it introduces. If there is any conflict in the usages of a word orterm in this specification and one or more patent or other documentsthat may be incorporated herein by reference, the definitions that areconsistent with this specification should be adopted.

As used herein, the phrase “at least one of” preceding a series ofitems, with the terms “and” or “or” to separate any of the items,modifies the list as a whole, rather than each member of the list (i.e.,each item). The phrase “at least one of” allows a meaning that includesat least one of any one of the items, and/or at least one of anycombination of the items, and/or at least one of each of the items. Byway of example, the phrases “at least one of A, B, and C” or “at leastone of A, B, or C” each refer to only A, only B, or only C; anycombination of A, B, and C; and/or at least one of each of A, B, and C.

What is claimed is:
 1. A metal matrix composite (MMC) tool, comprising:a hard composite portion that comprises a reinforcement materialinfiltrated with a binder material, wherein the reinforcement materialcomprises a refractory metal component dispersed with reinforcingparticles, wherein a surface roughness of the reinforcing particles isat least two times greater than a surface roughness of the refractorymetal component, wherein the refractory metal component has a failurestrain of at least 0.05 and a shear modulus of 200 GPa or less, andwherein the reinforcing particles have a failure strain of 0.01 or lessbut at least five times less than the failure strain of the refractorymetal component, and the reinforcing particles have a shear modulus ofgreater than 200 GPa and at least two times greater than the shearmodulus of the refractory metal component.
 2. The MMC tool of claim 1,wherein the reinforcing particles comprise particles of a materialselected from the group consisting of an intermetallic, a boride, acarbide, a nitride, an oxide, a ceramic, diamond, and any combinationthereof.
 3. The MMC tool of claim 1, wherein the refractory metalcomponent is selected from the group consisting of a refractory metal, arefractory metal alloy, and a combination of a refractory metal and arefractory metal alloy.
 4. The MMC tool of claim 3, wherein therefractory metal component has solidus temperature greater than 1500° F.and is selected from the group consisting of tungsten, rhenium, osmium,tantalum, molybdenum, niobium, iridium, ruthenium, hafnium, boron,rhodium, vanadium, chromium, zirconium, platinum, titanium, lutetium,palladium, thulium, scandium, iron, yttrium, erbium, cobalt, holmium,nickel, silicon, dysprosium, terbium, gadolinium, beryllium, manganese,copper, samarium, gold, neodymium, silver, germanium, praseodymium,lanthanum, calcium, europium, ytterbium, and any alloy thereof.
 5. TheMMC tool of claim 1, wherein the refractory metal component is atungsten metal powder and the reinforcing particles are a tungstencarbide powder.
 6. The MMC tool of claim 1, wherein the hard compositeportion comprises the refractory metal component at a concentrationranging from between 1% and 40% by weight of the reinforcement material.7. The MMC tool of claim 1, wherein the reinforcement material isinfiltrated with the binder material at a temperature greater than aliquidus temperature of the binder material but lower than a solidustemperature of the refractory metal component.
 8. The MMC tool of claim1, wherein the hard composite portion further comprises one or morelocalized hard composite portions comprising the refractory metalcomponent dispersed with the reinforcing particles at a concentrationranging between 80% and 100% by weight of reinforcement material.
 9. TheMMC tool of claim 1, wherein a gradient of concentration of therefractory metal component progressively decreases in a directionthrough the hard composite portion.
 10. The MMC tool of claim 1, whereinthe hard composite portion comprises a plurality of distinct layers ofvarying concentration of the refractory metal component.
 11. A drillbit, comprising: a bit body; and a plurality of cutting elements coupledto an exterior of the bit body, wherein at least a portion of the bitbody comprises a hard composite portion that comprises a reinforcementmaterial infiltrated with a binder material, wherein the reinforcementmaterial comprises a refractory metal component dispersed withreinforcing particles, wherein a surface roughness of the reinforcingparticles is at least two times greater than a surface roughness of therefractory metal component, wherein the refractory metal component has afailure strain of at least 0.05 and a shear modulus of 200 GPa or less,and wherein the reinforcing particles have a failure strain of 0.01 orless and at least five times less than the failure strain of therefractory metal component, and the reinforcing particles have a shearmodulus of greater than 200 GPa and at least two times greater than theshear modulus of the refractory metal component.
 12. The drill bit ofclaim 11, wherein the refractory metal component is selected from thegroup consisting of a refractory metal, a refractory metal alloy, and acombination of a refractory metal and a refractory metal alloy.
 13. Thedrill bit of claim 11, wherein the refractory metal component is atungsten metal powder or tungsten alloy powder and the reinforcementmaterial is a tungsten carbide powder.
 14. The drill bit of claim 11,wherein the hard composite portion comprises the refractory metalcomponent at a concentration ranging from between 1% and 40% by weightof the reinforcement material.
 15. The drill bit of claim 11, whereinthe refractory metal component and the reinforcement material areinfiltrated with the binder material at a temperature greater than amelting point of the binder material but lower than a solidustemperature of the refractory metal component.
 16. The drill bit ofclaim 11, wherein the hard composite portion further comprises one ormore localized hard composite portions comprising the refractory metalcomponent dispersed with the reinforcing particles at a concentrationranging between 80% and 100% by weight of reinforcement material. 17.The drill bit of claim 11, wherein a gradient of concentration of therefractory metal component progressively decreases in a directionthrough the hard composite portion.
 18. The drill bit of claim 11,wherein the hard composite portion comprises a plurality of distinctlayers of varying concentration of the refractory metal component.
 19. Adrilling assembly, comprising: a drill string extendable from a drillingplatform and into a wellbore; a drill bit attached to an end of thedrill string; and a pump fluidly connected to the drill string andconfigured to circulate a drilling fluid to the drill bit and throughthe wellbore, wherein the drill bit comprises a bit body and a pluralityof cutting elements coupled to an exterior of the bit body, and whereinat least a portion of the bit body comprises a hard composite portionthat comprises a reinforcement material infiltrated with a bindermaterial, wherein the reinforcement material comprises a refractorymetal component dispersed with reinforcing particles, wherein a surfaceroughness of the reinforcing particles is at least two times greaterthan a surface roughness of the refractory metal component, wherein therefractory metal component has a failure strain of at least 0.05 and ashear modulus of 200 GPa or less, and wherein the reinforcing particleshave a failure strain of 0.01 or less and at least five times less thanthe failure strain of the refractory metal component, and thereinforcing particles have a shear modulus of greater than 200 GPa andat least two times greater than the shear modulus of the refractorymetal component.
 20. The drilling assembly of claim 19, wherein thereinforcing particles comprise particles of a material selected from thegroup consisting of an intermetallic, a boride, a carbide, a nitride, anoxide, a ceramic, diamond, and any combination thereof, and wherein therefractory metal component is selected from the group consisting of arefractory metal, a refractory metal alloy, and a combination of arefractory metal and a refractory metal alloy.